JPH08300534A - Multi-layered sheet material and resin impregnated multi-layered sheet material, and manufacture thereof, and concrete panel comprising the resin impregnated sheet material - Google Patents

Abstract

PURPOSE: To ensure a lightweight and good handling property, and a formation retaining property by laminating in a manner adjoining mutually and in two or more layers a first layer having a multiplicity of noncontinuous independent fine interstices and small holes pierced in the thickness direction and a second layer having cavities communicated in the three-dimensional direction. CONSTITUTION: The multi-layered sheet material has a structure of a first layer A and second layer B that are laminated mutually adjacently and, at least, in two or more layers. The first layer A includes a multiplicity of independent fine interstices (dP) formed therein by which numerous noncontinuous cavities are formed in its inner part and, since the independent fine interstices (dP) exist, functions of heat insulation, shock elimination, or the like are given, in addition, a number of small holes (sP) pierced in the thickness direction serves an acoustic absorption effect. These layers are formed of independent foamed resin. On the other hand, the second layer B has continuous cavities formed in its inner part through a number of cavities existing therein and communicating in the three dimensional direction, so that it performs functions of lightweight as well as sound absorption, heat insulation, impact elimination and the like. These layers are formed of non-woven fabric.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a sound absorbing material, a heat insulating material, a shock absorbing material, a multilayer sheet material useful as a core material of a composite resin sheet, and a resin obtained by impregnating the multilayer sheet material with a resin. The present invention relates to an impregnated multi-layer sheet material, a method for producing the same, and a concrete panel comprising the resin-impregnated multi-layer sheet material, which is excellent in handleability and has high deformation resistance and dimensional accuracy.

[0002]

2. Description of the Related Art Nonwoven fabrics mainly made of glass fiber have been widely used as a sheet material for the purpose of sound absorption, heat insulation, shock absorption, etc., but recently, foamed resin having many voids inside. Seats are also used in various fields. Further, a fiber-reinforced composite resin material obtained by impregnating a fiber such as glass fiber as a reinforcing material with a resin is also widely used as an FRP material.

However, the glass fiber non-woven fabric which is most widely used as a sound absorbing / insulating material at the present time has a problem that glass fibers or small fragments thereof pierce the skin during the handling process to cause irritation or health problems. Moreover, since it itself lacks in shape retention, it is necessary to combine it with some kind of support material in order to put it into practical use for sound absorption and heat insulation.

Further, the FRP material in which the reinforcing fiber and the resin are compounded is very excellent in terms of cost and strength, but lightness is often required depending on its application. For example, there are movements to use FRP materials as an alternative to wood concrete panels, which have conventionally used lauan wood or the like imported from South Sea countries, but FRP materials are still more expensive than natural wood. In addition to being timber, it is also heavier than wood and difficult to handle and transport, which hinders its versatility.

[0005]

SUMMARY OF THE INVENTION The present invention has been made in view of the above circumstances, and its object is to improve the problems pointed out in conventional glass fiber non-woven fabrics and to provide it at a low cost. It is an object of the present invention to provide a multi-layer sheet material which is light in weight and excellent in handleability and shape retention, and a manufacturing method thereof. Another object of the present invention is to provide a resin-impregnated multi-layer sheet material useful as various panel materials, floor materials, wall materials, partition materials, outer plate materials, etc., using the above-mentioned multi-layer sheet material as a reinforcing material, and a method for producing the same. Is to establish. Still another object of the present invention is to provide a concrete panel which is excellent in deformation resistance and dimensional accuracy by using the above resin-impregnated multilayer sheet material and which can be economically manufactured at low cost. It is a thing.

[0006]

The structure of the multilayer sheet material according to the present invention, which has been able to solve the above-mentioned problems, has a large number of discontinuous independent fine spaces and a plurality of small holes penetrating in the thickness direction. The gist is that at least two or more layers of the first layer having the above and the second layer having a large number of voids communicating with each other in the three-dimensional direction are laminated adjacent to each other. An independent foaming resin is preferable as the first layer constituting material constituting the multilayer sheet, and a non-woven fabric is preferable as the second layer constituting material, and the second layer is formed in the small holes of the first layer in the multilayer sheet material. It is recommended that some of the fibers of the non-woven fabric have penetrated into the non-woven fabric because the integrity of both layers is enhanced by a simpler structure.

In the multi-layer sheet material, the outermost surface side of the sheet has an odd-numbered laminated structure in which both surfaces are composed of the first layer, so that the appearance and structural characteristics of the sheet material and the handleability are further improved. Can be excellent, and can be at least the first of the sheet materials.
By forming a large number of see-through holes in the thickness direction of the layer, it is possible to obtain the advantage that the sound absorbing effect and the like of the obtained multilayer sheet material is further enhanced, and it is obtained by impregnating and solidifying the multilayer sheet material with a resin. The effect that the transparency of the resin-impregnated multilayer sheet material is enhanced can also be enjoyed.

The resin-impregnated multi-layer sheet material according to the present invention has a structure in which a resin is impregnated and solidified in the small holes of the first layer and the large number of voids of the second layer in the multi-layer sheet material having the above-mentioned structure. It has a gist where. In this resin-impregnated multilayer sheet material, a large number of see-through holes are formed penetrating in the thickness direction of the first-layer constituent material, and the small holes and the see-through holes of the first layer and the plurality of voids of the second layer are formed. It is preferable that the light-transmissive resin is impregnated and solidified therein, because the resin-impregnated multilayer sheet material can be provided with transparency. In addition, the resin-impregnated multilayer sheet material having both sides reinforced with fiber-reinforced resin layers is extremely useful because it has more excellent strength characteristics.

The above-mentioned resin-impregnated multilayer sheet material, in particular, the intermediate layer of the multilayer sheet material constituting the sheet material is constituted by the second layer, and both sides thereof are reinforced by the fiber reinforced resin layer A sheet material, especially a double-sided reinforced resin-impregnated multi-layer sheet material in which a transparent hole is formed in the first layer and a light-transmissive resin is impregnated and solidified as a resin to give transparency in the laminated thickness direction is extremely useful as a synthetic concrete panel. Is.

Further, the method for producing the multilayer sheet material according to the present invention is as follows:
By laminating at least two layers of the first layer having a large number of discontinuous and independent fine spaces and the second layer made of a non-woven fabric adjacent to each other, and performing needle punching from at least one side of the laminated body, A large number of small holes penetrating in the thickness direction are formed in the first layer, and at the same time, a part of the fibers of the non-woven fabric forming the second layer is allowed to penetrate into the small holes, whereby the first layer and the second layer are integrated. The point is to enhance the sex.

The resin-impregnated multi-layer sheet material according to the present invention is laminated on both surfaces of the multi-layer sheet material while the resin liquid is applied to the reinforcing fibers constituting the fiber-reinforced resin layer, It can be easily manufactured by infiltrating the fibers and the small holes of the first layer in the multilayer sheet material or the holes and the transparent holes and the voids of the second layer to solidify the fibers.

[0012]

ACTION AND EXAMPLES Under the circumstances as described above, the present inventors solve the problems pointed out in ordinary glass fiber non-woven fabric sheets and provide an inexpensive sheet material exhibiting performance exceeding it. Together with the high-performance resin-impregnated sheet material using the sheet material, further, as a result of earnest research for the development of a method capable of industrially producing these sheet materials, the above-mentioned present invention It is a thought.

The structures of the multilayer sheet material, the resin-impregnated multilayer sheet material and the method for producing them according to the present invention, and the concrete panel made of the resin-impregnated multilayer sheet material will be described in detail below.

The multilayer sheet material according to the first aspect of the present invention is
For example, as shown in FIG. 1 schematically showing its cross-sectional structure, it basically has a structure in which at least two layers (three layers in the illustrated example) are laminated such that a first layer A and a second layer B are adjacent to each other. The first layer A has a large number of discontinuous and independent fine spaces dP formed therein, and also has a plurality of small holes sP penetrating in the thickness direction, while the second layer B is It has a large number of voids communicating in the three-dimensional direction.

That is, the first layer A is lightened by forming a large number of discontinuous voids inside due to the large number of independent fine spaces dP formed therein, and the presence of the independent fine spaces dP. It exhibits various functions such as heat insulation and shock absorption, and further constitutes a resin non-impregnated part when it is used as a constituent material of a resin-impregnated multilayer sheet material described later, and maintains a constant thickness and shape as a whole layer. . There are various materials for forming such a layer, and examples thereof include an independent foaming type resin sheet, balsa material, cork, etc., but cost, availability, and the number and size of independent fine spaces dP. Well,
The most preferable is the independent foaming type resin in view of comprehensively considering quality stability including physical properties, and specifically, the independent foaming type polyurethane resin, polystyrene resin,
Examples thereof include polyvinyl chloride resin, polyethylene resin, polypropylene resin and the like. Of these, the more general are foamed polyethylene-based resins and foamed polypropylene-based resins.

These independent foaming type resins have a porosity of 10 to 80 in order to more effectively exert various functions such as a weight-reducing effect, heat insulation and impact relaxation due to the independent fine space dP existing inside thereof. % By volume, more preferably 30
It is preferable to use one having a range of ˜50% by volume.

The first layer A has a plurality of small holes s penetrating in its thickness direction in addition to the large number of independent fine spaces dP.
This small hole sP mainly exhibits a sound absorbing effect, and also acts as a resin impregnating void when it is used as a constituent material of a resin-impregnated multilayer sheet material described later, and is integrated with the second layer B. Play an important function in enhancing. The size and number of the small holes sP are not particularly limited, but in order to effectively exhibit the above effect, the hole diameter is about 0.5 to 3 mm,
More preferably, the small hole sP of about 1 to 2.5 mm is 500.
It is preferably about 1,000,000 pieces / m ² , more preferably about 50,000 to 500,000 pieces / m ² . The thickness of the first layer A cannot be uniformly specified because it varies depending on the application, required characteristics, and the total number of laminated layers including the second layer B, but it is usually 1 to 50 mm, preferably It is selected from the range of 5 to 10 mm.

In addition to the large number of small holes sP, it is also effective to form a see-through hole slightly larger than the small holes sP in the first layer A. The see-through hole H will be described in detail later. Its function is to enhance the sound absorption characteristics of the multilayer sheet material itself, and to impregnate the multilayer sheet material with a resin as described later to provide a concrete panel or the like. When used as, it exerts an effect of enhancing the transparency in the thickness direction of the laminate.

On the other hand, the second layer B is made lighter by forming continuous voids inside due to the large number of voids communicating in the three-dimensional direction existing therein, and also has various functions such as sound absorption, heat insulation, and shock absorption. Further, the resin-impregnated portion is used when it is used as a constituent material of a resin-impregnated multilayer sheet material described later, and the resin-impregnated portion exerts an effect of increasing the structural strength.
There are various materials that make up such layers,
Examples include continuous foaming type resin sheets, fibrous non-woven fabrics, woven fabrics, knitted fabrics, etc. Among them, the most common ones are fibrous non-woven fabrics. The constituent materials of the fibrous non-woven fabric can be all organic or inorganic, natural or synthetic, and may be appropriately selected and determined from among these depending on the characteristics required for the multilayer sheet material. The most preferable fiber nonwoven fabric made of synthetic fiber such as polyester fiber, acrylic fiber, polyamide fiber and the like in view of handling property and cost, etc. Can be said to be the most common. In addition, by adding conductivity to the multilayer sheet material by using carbon fibers or metal fibers, or by using hygroscopic fibers (including those in which water-absorbent resin powder is mixed in the nonwoven fabric) It is also recommended as a preferred embodiment to obtain a moisture-absorbing / water-absorbing multilayer sheet material.

The form of the fibrous nonwoven fabric used as the constituent material of the second layer B is not limited at all, and is appropriately selected in consideration of the lightness and various functions such as sound absorption, heat insulation and impact relaxation required for the intended multilayer sheet material. Select and decide. The second layer B
The thickness can vary depending on the application, the required characteristics, and the total number of laminated layers including the first layer A, and therefore cannot be specified uniformly, but is usually 0.5 to 20 mm, preferably 2 to 10 mm. It is selected from the range.

The first layer A and the second layer B are laminated in the simplest two-layer structure of the first layer and the second layer, that is, the first layer and the second layer.
3 layers structure of layer-first layer (laminated structure of FIG. 1), or 4
Although a multi-layer laminated structure of more than one layer is included, the most practical one is a 2- to 5-layer structure considering the workability of laminating, etc. Especially, both sides as a multi-layer sheet material are finished to be smooth and easy to handle and retain shape. In order to enhance the above, an odd-numbered laminated structure having three layers or five layers in which the first layer constituent material is provided on both sides and the second layer constituent material is sandwiched in the center.

The method for laminating and integrating the first layer A and the second layer B is not particularly limited, and, for example, a method of joining the entire surface or spots with an appropriate adhesive can be adopted. However, as a method of easily integrating both layers without impairing the characteristics of the respective constituent materials, the following method can be mentioned. That is, for example, as shown in FIG.
2nd layer B First layer A
After superposed with the constituent materials, a needle punch N (1 is a needle body, 2 is a fiber hooking portion) having a sectional structure as shown in an enlarged view in FIG. 3 is used to penetrate in the thickness direction of the laminate. Needle punching [Fig. 2 (B), (C)]
And the small holes sP are formed in the first layer A, and a part of the non-woven fabric fiber 3 forming the second layer B is partially cut by the needle punch N.
This is a method in which a part of the non-woven fabric fiber 3 is caused to enter the small holes sP formed in the first layer A by being hooked on the hooking portion 2. Then, the size of the small hole sP and the non-woven fabric fiber 3 to the small hole sP are adjusted by appropriately adjusting the sizes of the needle body 1 and the hooking portion 2 that form the needle punch N at this time.
The amount of penetration of the small holes sP can be freely controlled by adjusting the amount of penetration of the small holes sP and the like, and by changing the interval and the number of the needle punching. It is possible to arbitrarily control the degree of integration of the two layers B.

Therefore, this method constitutes one of the methods of the present invention as the most effective method for producing a multilayer sheet material, and the first layer A obtained by such a method.
The multi-layer sheet material having a structure in which a part of the non-woven fabric fibers 3 constituting the second layer B penetrates into the small holes sP of the first layer A and the second layer B.
One of the present invention is configured as a multi-layer sheet material having a peculiar structure in which is integrated without using an adhesive or the like. The non-woven fabric fibers 3 that enter the small holes sP of the first layer by the needle punching process are, for example, as shown in FIG.
As shown in (C), the state of being pulled out to the outside of the small hole sP enhances the integrity of the laminated body and reduces the surface unevenness of the first layer A formed by the perforation, and Is also preferable for enhancing the surface smoothness when the resin is impregnated and solidified as described later.

FIG. 4 is a partial sketch drawing illustrating a multi-layer sheet material manufactured by the above method, with first layers A, A having a large number of independent fine spaces dP (not shown in the drawing) sandwiched therebetween. A second layer B made of a non-woven fabric is laminated between them, and a large number of small holes sP are formed in the first layers A and A by penetrating the laminated body in the thickness direction and performing the needle punching treatment as described above. The figure shows a state in which a part of the non-woven fabric fiber 3 is made to penetrate into the small hole sP while being formed.

Incidentally, H shown in FIG. 4 is a see-through hole which may be formed in the multilayer sheet material, and the see-through hole H is a small hole s.
It can be formed to be slightly larger than P and can be formed at any density according to the purpose, and exhibits an effect of enhancing the sound absorption characteristics of the multilayer sheet material, and impregnates the multilayer sheet material with a resin as described later. When it is used as a concrete panel or the like, it has the effect of increasing the transparency in the thickness direction of the laminate. The size and forming density of the see-through holes H are not particularly limited, but the size is preferably 1.5 to 15 mm, and more preferably 2 in order to effectively exhibit the above-mentioned function.
The formation density is about ^{2 to} 20 pieces, more preferably about 4 to 15 pieces, per 1 m ² .

The thus obtained multi-layer sheet material having the above-mentioned structure is used, for example, as a heat insulating material, a sound absorbing material, a shock absorbing material, a building wall material, a floor material, a ceiling material, a packing material for packing, a speaker, etc. It can be widely used as an acoustic lining material, a lining material for a heat insulating container such as a cooler box, and can be effectively used as a core material for a resin-impregnated sheet material as described in detail below.

Next, the resin-impregnated sheet material according to the present invention will be described. The resin-impregnated sheet material of the present invention has a structure in which the resin is impregnated and solidified in the small holes sP (and the transparent holes H) in the first layer A and the voids in the second layer B in the above-described multilayer sheet material. For example, as shown in FIG. 5, the resin is impregnated and solidified in the small holes sP (and the transparent holes H and the small holes sP) and in the voids of the second layer B. The two layers B are integrally joined to form a resin-impregnated multilayer sheet material having a strong laminated structure. The laminated structure of the resin-impregnated multilayer sheet material can be freely changed by changing the laminated structure of the multilayer sheet material used as the core material.
When a multi-layer sheet material in which one layer each of the second layer B and the second layer B is laminated is used, a resin-impregnated multi-layer sheet material having a structure in which a resin is impregnated and solidified in a two-layer laminated structure is obtained, and the first layer A and the second layer
If a multilayer sheet material in which two layers B are alternately laminated is used, a resin-impregnated multilayer sheet material having a structure in which a resin is impregnated and solidified in a four-layer laminated structure can be obtained.

In this resin-impregnated multi-layer sheet material, the independent fine spaces dP in the first layer A serve as resin non-impregnated portions to enhance the lightness, and therefore, compared with conventional fiber-reinforced resin panels and the like. The resin layer is light-weight and impregnated and solidified in the voids of the second layer B having voids communicating in the three-dimensional direction, and further penetrates into the small holes (and the transparent holes H) in the first layer A. Combined with the pillar effect of the solidified resin, it has both excellent structural strength and light weight.

It has been stated that the preferred structure of the multilayer sheet material is, for example, an odd laminated structure in which both sides are composed of the first layer A as shown in FIG.
Even when the resin-impregnated multilayer sheet material is used, such an odd-numbered laminated structure is preferable. However, in the case of the odd-numbered laminated structure, the intermediate layer portion of the laminated structure is inevitably composed of the second layer B, and the second layer B is formed in the three-dimensional direction like the fiber nonwoven fabric as described above. The second layer B which has voids communicating with each other and constitutes an intermediate layer in a state where the resin is impregnated and solidified.
This is because the resin is impregnated and solidified therein to form a reinforced core portion, and thus a resin-impregnated multilayer sheet material having a high structural strength as a whole and hardly causing warping or the like can be obtained.

Another preferable laminated structure of the resin-impregnated multilayer sheet material is, for example, one in which the intermediate layer and both outer surface side layers of the laminated body are both constituted by the second layer B as shown in FIG. With such a laminated structure, however, the resin is impregnated and solidified in the voids of the second layer B on both outer surfaces in the state where the resin is impregnated and solidified, and as a result, both outer surfaces are fiber-reinforced. This is because a resin-impregnated multi-layer sheet material having excellent surface strength characteristics can be obtained by being configured with a resin layer.

When the first layer A having the see-through hole H as shown in FIG. 4 is used, the see-through hole H serves as a thick pillar connecting the first layer A and the second layer B. It acts to further increase the structural strength as a whole, and when a light-transmissive resin is used as the impregnating resin, the thick transparent hole H
Acts as a light-transmitting part, and exhibits an excellent effect when used as a panel material for ceiling, ceiling material, wall material, etc., and when used as a concrete panel material, the inside of the panel material It is preferable because it can be used for confirmation from the outside of the filling position of the concrete material to be filled in.

As another preferred structure of the resin-impregnated multilayer sheet material according to the present invention, for example, as shown in FIG. 7, a fiber-reinforced resin layer FRP is formed on both sides of the resin-impregnated multilayer sheet material to reinforce both sides. A double-sided reinforcing resin-impregnated multi-layer sheet material can be mentioned. That is, as shown in FIG. 5, the resin-impregnated multi-layer sheet material having the first layer A on both sides is substantially not impregnated with resin except for the small holes sP (or the transparent holes H) on both sides. Since the surface is exposed, the surface strength may become insufficient, but if the structure is one in which the fiber reinforced resin layer FRP is laminated on both sides, the surface strength will be very excellent. Because you can get it.

As the reinforcing fibers used in the fiber-reinforced resin, non-woven fabrics made of glass fibers, chopped strands, roving cloth, etc. are most commonly used from the viewpoint of effectively utilizing the purpose of surface reinforcement. Of course, it is also possible to use it together with metal fibers and organic fibers.
Further, the preferable thickness of the fiber reinforced resin layer FRP should be arbitrarily determined according to the required surface strength and cannot be uniformly defined, but usually 0.5 to 10 m.
It is better to select from the range of about m, more generally about 1 to 5 mm.

The surface-reinforced resin-impregnated multilayer sheet material thus obtained exhibits excellent effects for synthetic concrete panels because of its excellent surface strength characteristics. In particular,
When the intermediate layer of the laminated structure is composed of the second layer B, the second layer B impregnated and solidified with the resin can significantly suppress warping and bending due to the strengthening effect of the intermediate portion. It is preferable to use the layer A because the concrete filling amount inside can be confirmed from the outside through the see-through hole H as described above and the practical value as a concrete panel can be further enhanced.

There is no particular limitation on the type of impregnating resin used in the production of the above resin-impregnated multilayer sheet material, and unsaturated polyester resins, epoxy resins, vinyl ester resins, polyurethane resins, alkyd resins are used. Thermosetting resin such as phenol resin, furan resin, melamine resin, urea resin; acrylic resin, polystyrene resin, polyolefin resin (polyethylene, polypropylene, etc.), polyvinyl chloride resin, vinylidene chloride resin Resin, polyamide resin, saturated polyester resin,
A thermoplastic resin such as an acetal resin can be used, and the type of the impregnating resin may be appropriately selected and determined depending on the use and the required characteristics of the resin-impregnated multilayer sheet material, but among these, the most common is Thermosetting resins such as saturated polyester resins, epoxy resins, and vinyl ester resins.

Next, a preferred method for producing the multilayer sheet material and the resin-impregnated multilayer sheet material according to the present invention will be described.
FIG. 8 is a schematic process explanatory view illustrating the method for producing a multilayer sheet material according to the present invention, and the materials used, that is, the constituent materials of the first layer A and the second layer B are as described above. Further, in FIG. 8, a three-layer laminated structure is described as an example of the laminated structure, but as described above, the laminated structure can be applied to a two-layer structure or a multilayer structure of four or more layers. The method of the present invention can be implemented with appropriate modifications according to the following method even for such different laminated structures.

In producing a multi-layer sheet material having a three-layer laminated structure, two raw material rolls A obtained by winding the first layer A constituent material are wound.
_One raw material roll B _{1 obtained} by winding ₁ , A ₂ and the second layer B constituent material
The respective materials are drawn out from each other, the first layer A is superposed on both surfaces of the second layer B with the second layer B sandwiched therebetween, and then needle punching is performed by the needle punching device 8 on the downstream side to penetrate the first layers A and A. Form a large number of small holes. In this needle punching step, as shown in FIG.
A needle punch N provided with a fiber hooking portion 2 is used, and at the same time when the small hole is formed, a part of the non-woven fabric fiber constituting the second layer B is intruded into the small hole [Fig. 2 (A)-( C)
reference]. Then, if necessary, it may be shaped through the pressure shaping unit 9 and then wound. The size and number of the small holes formed in the raw material windings A ₁ and A ₂ can be freely changed by changing the interval of the needle punch and the needle size.

When the transparent hole H is formed in the first layer A as shown in FIG. 4, the material in which the transparent hole H is formed in advance is wound into raw material rolls A ₁ and A _2. The method used, the method of performing the punching treatment on the upstream side before laminating with the second layer in FIG. 8 to form the see-through hole H, or the second layer B on the upstream side or the downstream side of the needle punching device 8. It is possible to employ a method in which punching treatment is performed in the laminated body in the thickness direction to form a see-through hole penetrating in the entire thickness direction of the laminated body. The thus obtained multilayer sheet material is the multilayer sheet material of a preferred embodiment according to the present invention, in which a part of the non-woven fabric fiber constituting the second layer B has penetrated into the small holes formed in the raw material rolls A ₁ and A _2. Become.

Next, a method for manufacturing the double-sided resin impregnated multilayer sheet material according to the present invention will be described with reference to FIG. In carrying out the method shown in FIG. 9, it is preferable to use, for example, a device (not shown) for moving a releasable film made of, for example, a polyester type or a polyvinyl alcohol type, on the most upstream side of the manufacturing line. The resin liquid Ra for impregnation is supplied onto the film Fa, and the reinforcing fiber material (nonwoven fabric, woven / knitted material, chopped strands, etc.) Ga is supplied thereon, and a large amount of the resin liquid Ra is further provided thereon. After the supply, the multi-layer sheet material S manufactured by the above method is superposed on it. Then, on the downstream side, the same reinforcing fiber material Ga as above is supplied onto the multilayer sheet material S, and the impregnating resin liquid Ra is supplied to the upper surface of the second reinforcing sheet material Ra.
By superposing the films Fb and pressing them with an appropriate pressure by a belt, a roll or the like, the resin liquid Ra is added to the small holes of the first layer in the multilayer sheet material S or the small holes of the resin liquid Ra and the transparent holes and the second layer. It is made to infiltrate into the void and sent to the heating and solidifying chamber 10 to solidify and shape the impregnated resin. At this time, if necessary, the air is cooled by passing through the air cooling chamber 11 on the downstream side. After that, the first and second films Fa and Fb on the front and back surfaces of the molded body whose surface has been shaped are peeled and removed, or if they are not removed and cut as they are to a predetermined size with the cutter 12, as described in FIG. A double-sided reinforcing resin-impregnated multilayer sheet material 13 having a simple laminated structure is obtained. The first and second films Fa and Fb used here have a function of holding the unreinforced or semi-solidified reinforcing fiber materials Ga and Ga and preventing the impregnated resin from leaking out and performing surface shaping. For example, cellophane, vinylon, tetron, etc. are used as the film, and these may be peeled and reused after solidification of the impregnated resin as described above, or they may be cut as they are while being adhered to both surfaces. It can also be used as a protective film for a panel.

The method for producing the double-sided resin impregnated multilayer sheet material has been described above. However, in the case of producing the resin impregnated multilayer sheet material having the laminated structure as shown in FIG. Reinforcing fiber materials Ga, Ga in manufacturing examples
Is omitted, and the following may be carried out in exactly the same manner as described above.

However, the production example shown in FIG. 9 shows a preferable method for continuously producing the resin-impregnated multilayer sheet material of the present invention or the double-sided reinforcing material thereof, and the production method thereof is The method is not limited to the above, and in addition to the above method, it is also possible to adopt a method of impregnating the resin liquid by an impregnation drawing method, a hand layup molding method, a spray up molding method, or the like. When manufacturing relatively small sizes, the so-called resin injection impregnation molding method or vacuum bag impregnation molding method in which the above-mentioned multilayer sheet material is loaded into the sealed mold and the impregnating resin liquid is injected. It is also possible to adopt such as.

[0042]

The present invention is constructed as described above, and its applications and features are summarized below. Multi-layer sheet materials: For example, heat insulation and moisture proofing used for building materials,
It can be effectively used as a wall material or floor material for soundproofing and interior applications, and also as a core material for producing a resin-impregnated multilayer sheet material as described below.

Resin-impregnated multi-layer sheet material: Lightness can be maintained even after resin impregnation due to the presence of the first layer having a large number of independent fine spaces, and the strength is the resin for the second layer having three-dimensional voids. Impregnation and solidification and bridging (pillar) with resin solidified by entering the small holes (and see-through holes) formed in the first layer
It is a composite resin sheet that is secured by the effect and is lightweight and has high structural strength. It can be used for various purposes by utilizing its own characteristics, and it can be secondary molded into any shape by subsequent heat and pressure. It can be applied to various uses such as various preformed sheet materials.

Double-sided reinforcing resin-impregnated multilayer sheet material: Both sides of the resin-impregnated multilayer sheet material are reinforced by fiber reinforced resin, and the surface strength of the resin-impregnated multilayer sheet material is reinforced and the structural strength as a whole is also increased. It is widely used as a variety of large and small molding materials such as bathtubs, domes, vehicle panels and spoilers, tanks, boats, etc., which require higher structural strength and surface strength than the above. be able to.

Concrete panel: The above-mentioned double-sided reinforcing resin-impregnated multi-layer sheet material, which has a large number of independent fine spaces, most of which constitute the resin non-impregnated portion.
The intermediate layer is made up of the second layer that constitutes the resin-impregnated portion, and the structural strength is also obtained by bridging the solidified resin into the small holes (and the see-through holes) of the first layer while the weight is reduced by stacking the layers. Since it is raised, and both sides are reinforced by the fiber reinforced resin layer, it becomes a concrete panel with excellent performance that can be used repeatedly many times. Moreover, when the transparent hole is formed in the first layer and the light-transmissive resin is used as the impregnating resin, it becomes possible to confirm the filling amount of the concrete filled inside through the transparent hole from the outside. You can enjoy great advantages in. Furthermore, according to the manufacturing method of the present invention, the multilayer sheet material and the resin-impregnated multilayer sheet material or the double-sided reinforcing material thereof can be manufactured with high productivity by a relatively simple method.

[Brief description of drawings]

FIG. 1 is a partial cross-sectional explanatory view illustrating the configuration of a multilayer sheet material according to the present invention.

FIG. 2 is an explanatory view illustrating the method for producing a multilayer sheet material according to the present invention.

FIG. 3 is an explanatory view showing the structure of a needle punch N used in the present invention.

FIG. 4 is a partial cross-sectional explanatory view illustrating the structure of another multilayer sheet material according to the present invention.

FIG. 5 is a partial cross-sectional explanatory view illustrating the structure of a resin-impregnated multilayer sheet material according to the present invention.

FIG. 6 is a partial cross-sectional explanatory view illustrating the structure of another resin-impregnated multilayer sheet material according to the present invention.

FIG. 7 is a partial cross-sectional explanatory view illustrating the structure of a double-sided reinforcing resin-impregnated multilayer sheet material according to the present invention.

FIG. 8 is an explanatory view illustrating the method for producing a multilayer sheet material according to the present invention.

FIG. 9 is an explanatory view illustrating a method for producing a resin-impregnated multilayer sheet material and a double-sided reinforcing body thereof according to the present invention.

[Explanation of symbols]

 A 1st layer B 2nd layer sP Small hole dP Independent fine space H Transparent hole 1 Needle body 2 Fiber hooking projection 4 Needle punching device S Multi-layer sheet material Ra Impregnating resin liquid Ga Reinforcing fiber Fa, Fb 1st, 1st 2 film 10 heating and solidifying chamber 12 cutter

 ─────────────────────────────────────────────────── ─── Continuation of the front page (72) Inventor Hiroshi Taruki 8-1 Techno Park, Sanda City, Hyogo Prefecture Mitsui Plant, Nippon Polyester Co., Ltd. (72) Masatake Fujiwara 2-5-25 Tenjinbashi, Kita-ku, Osaka Sansho Tsusho Co., Ltd.

Claims (12)

[Claims] 1. A plurality of discontinuous independent fine spaces,
The first layer having a small hole penetrating in the thickness direction and the second layer having a void communicating with the three-dimensional direction are adjacent to each other and at least two layers are laminated. Multi-layer sheet material. 2. The multilayer sheet material according to claim 1, wherein the first layer is made of an independent foaming resin, and the second layer is made of a nonwoven fabric. 3. The multilayer sheet material according to claim 2, wherein some of the fibers of the non-woven fabric forming the second layer penetrate into the small holes of the first layer. 4. The first layer and the second layer are alternately laminated, and the outermost surface side has an odd laminated structure in which both surfaces are constituted by the first layer. The described multilayer sheet material. 5. The multilayer sheet material according to claim 1, wherein a large number of transparent holes are formed in at least the thickness direction of the first layer. 6. The multilayer sheet material according to claim 1, wherein a resin is impregnated in the small holes of the first layer or in the small holes and the transparent holes and in the large number of voids of the second layer. A resin-impregnated multilayer sheet material characterized by being solidified. 7. The resin-impregnated multilayer sheet material according to claim 6, wherein the multilayer sheet material is impregnated with a light-transmissive resin and solidified. 8. A resin-impregnated multilayer sheet material having both sides reinforced, wherein a fiber reinforced resin is laminated on both sides of the resin-impregnated multilayer sheet material according to claim 6 or 7. 9. A concrete panel comprising the double-sided reinforced resin-impregnated multilayer sheet material according to claim 8, wherein an intermediate layer of the multilayer sheet material is constituted by a second layer. 10. A method for producing a multilayer sheet material according to claim 1, wherein the first layer having a large number of discontinuous and independent fine spaces and the second layer made of a non-woven fabric,
By laminating at least two layers adjacent to each other and performing needle punching from at least one side of the laminated body, a large number of small holes penetrating in the thickness direction are formed in the first layer, and at the same time, the second layer is formed. A method for producing a multi-layer sheet material, characterized in that a part of the fibers of a non-woven fabric forming a layer is allowed to penetrate into the small holes. 11. A resin liquid is applied to the multilayer sheet material according to claim 1, and the small holes in the first layer of the multilayer sheet material or the small holes and the transparent holes and the second layer are formed. A method for producing a resin-impregnated multilayer sheet material, which comprises impregnating and solidifying the resin liquid in the voids. 12. The multilayer sheet material according to claim 1, is laminated on both surfaces in a state where a resin liquid is applied to the reinforcing fibers constituting the fiber-reinforced resin layer, Reinforcing resin-impregnated multi-layer sheet material having both sides reinforced fiber and infiltrating into the small hole of the first layer of the multi-layer sheet material or the transparent hole and the void of the second layer to solidify Manufacturing method.